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Narrator:
Today on "How it's made"...
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Bronze bells...
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...Wooden airplane propellers...
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...Charcoal briquettes...
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...And gas-log fireplaces.
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Throughout history,
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Bells have played both practical
And ceremonial roles.
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Village bells would ring
To mark time
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And to warn of danger.
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Church bells would toll
To summon worshipers.
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Bells are traditionally cast
Of bronze,
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A metal that's as durable
As it is melodic.
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[ bells tolling ]
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When it comes to bell making,
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There'd be neither swing
Nor ring without a mold.
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And only a quality mold
Makes a quality bell.
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The mold is made
Using a pattern.
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This particular bell will have
Decorative lines on the surface,
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Which will require
A separate mold
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Made from this
Five-piece pattern.
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After greasing the pattern's
Surface with a release agent,
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Workers lower a wooden casing
Around it.
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This casing
Will hold the mixture
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Of fine silica sand and epoxy
They'll use to make the mold.
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Workers pack the material
Tightly
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Between the pattern and casing.
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The epoxy sets in 10 minutes,
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And now they have a sand mold
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In which to cast
The bell's decorations.
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They still need a mold
To cast the bell itself.
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They make it
With this aluminum pattern.
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After spraying it inside and out
With a release agent,
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They lower the decoration mold
They just made right over it...
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Then on top of that, a steel
Casing to contain the sand mix.
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Workers pack the sand mix
And wait for it to set.
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Then they flip the casing
And add another section
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To hold even more sand mix.
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But before the next load
Of sand,
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They insert what's called
The gate.
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This aluminum rod
Shapes the channel
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Through which they'll pour
The molten bronze
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Into the mold cavity.
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They fill up the mold
With more sand.
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Then they form a funnel
Around the central channel
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Because
It's virtually impossible
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To pour molten bronze directly
Into such a small hole.
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They poke the sand mix
To make sure it's set,
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Then pull out the gate.
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They separate the two casings,
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Each of which contains
A section of the mold.
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Then the patterns come out,
Leaving behind the mold cavity.
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Workers tidy up the mold walls
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And paint on
A powdered graphite solution
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Which will act as a barrier,
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Preventing the hot metal
From eroding the epoxy
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That holds the sand mold
Together.
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Next, they spray on
A second coat of wash.
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The sand is so fine
That without this step,
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The mold would reproduce
The brush strokes
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Onto the cast bell.
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Now they measure the size
Of the pour hole
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And custom-make a ceramic filter
To glue inside.
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This filter will screen out
The slag,
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Oxidized particles that form
When molten metal meets air.
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Workers stack the two mold
Sections back together
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And clamp them tightly so that
The bronze won't leak out
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During casting.
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Melting enough bronze ingots
For an average-size bell
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Takes about two hours.
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To get a smooth enough
Consistency,
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The furnace has to heat the
Metal to about 2,100 degrees.
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For a quality casting,
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They must pour the bronze
In one continuous flow --
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No stops and starts.
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The funneling basin they made in
The sand prevents overflowing.
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The bronze takes about
A half-hour to solidify
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And up to 24 hours to cool.
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Workers remove the sand mold
With a jackhammer,
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Being very careful not to hit
The bell inside.
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The extracted bell is covered
In a residue of burnt epoxy,
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Which they remove
With a wire brush.
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Then, with one well-aimed strike
Of a sledgehammer,
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They disengage the gate.
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Now they mark the exact
Center point of the bell.
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That's where they'll install
The hardware
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From which the bell will hang.
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They drill a small hole,
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Then gradually drill it larger
And larger.
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A big hole can't be bored
In one shot
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Because the friction-induced
Heat would crack the bell.
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Workers tip the bell on its side
To hang the clapper --
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The official name
For the bronze hammer inside.
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Every bell this factory produces
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Goes through six stages
Of polishing,
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Starting with
A coarse grinding belt
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And finishing with
A fine-cloth buffing wheel.
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Two hours of polishing later,
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The bell looks as beautiful
As it sounds.
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[ bells tolling ]
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Coming up...A new spin
On a centuries-old invention --
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The wooden propeller.
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Narrator: the propeller
Dates back to 1493,
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When leonardo da vinci
Sketched out
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The concept for a helical screw
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That could propel a machine
Vertically into the sky.
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The propeller is still
Occasionally referred to
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As an airscrew --
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A term that accurately reflects
Its basic design and function.
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The key to making one --
Plenty of sanding.
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Wooden propellers start out as
A laminated block of maple wood.
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Lamination is a process
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Where several layers
Are glued together.
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The block
Has between 36 and 48 layers
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Less than 1/16 of an inch thick.
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Depending on the model,
Workers select a master pattern
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That is between one
And two yards long.
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They lay this pattern
Over the maple block
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And mark a one-inch center hole.
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They drill the hole...
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And lay in a centering pin
To hold the pattern in place.
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A worker traces the pattern
On the top of the block.
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He then cuts the outline
With a band saw.
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This is the propeller's profile.
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00:07:46,586 --> 00:07:49,655
Next, he traces a pattern
On the side of the block.
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This is the propeller's pitch --
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The amount of twist
In the blades,
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00:07:53,620 --> 00:07:57,241
Which dictates the amount
Of propeller thrust.
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Using a pattern guide,
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He marks where the pitch
Blends into the center hub,
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00:08:02,206 --> 00:08:05,344
Then removes the bulk
Of the pitch with a band saw.
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Now he clamps the block onto a
Computer-guided milling machine
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That carves the pitch
To very precise dimensions.
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The machine's
Carbide-tipped cutters
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Shave infinitesimal amounts
Of wood with each pass.
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Precision milling
Just one end of the propeller
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Can take up to 60 passes.
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Next, a worker shapes
The airfoil with a band saw.
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The airfoil is the side
Of the propeller
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That is shaped
Like an airplane wing
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And produces forward thrust.
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The pitch side...
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And the airfoil side.
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Workers use a tool
Called a spokeshave
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To smooth the propeller
Even more.
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00:09:34,517 --> 00:09:37,344
Then they verify the airfoil's
Thickness and curve
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With a hand gauge.
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A spray of dark paint helps them
Know where they've been
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As they begin smoothing
The propeller's surface.
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They remove any remaining
Carving marks
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Using a belt sander.
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00:10:00,103 --> 00:10:03,275
Then they check the propeller
For balance.
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00:10:08,310 --> 00:10:10,482
Using a pneumatic sanding drum,
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00:10:10,482 --> 00:10:12,655
They perform an overall sanding
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00:10:12,655 --> 00:10:15,862
And punch in propeller
Specifications --
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Diameter, pitch,
Flight direction symbols,
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And manufacturer I.D.
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00:10:20,862 --> 00:10:23,206
Workers hand-inspect
The propeller,
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00:10:23,206 --> 00:10:26,724
Then perform a final sanding
And balance.
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00:10:33,068 --> 00:10:36,034
A coat of clear enamel
Seals the wood.
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And a safety color
Sprayed on the tips
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Makes the propeller visible
While it's spinning.
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00:10:47,379 --> 00:10:50,172
Two final protective coats
Of clear enamel,
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24 hours of drying time,
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And these propellers
Are ready for takeoff.
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When we return,
Fire up the grill.
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It's time to make
Some charcoal briquettes.
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Narrator: the charcoal briquette
Was invented in 1897,
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But interest in it was
Slow-burning, so to speak,
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Until the 1920s.
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That's when automaker henry ford
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Decided to recycle wood scraps
From car making
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Into barbecue briquettes,
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00:11:23,965 --> 00:11:27,586
And these little nuggets
Became a smoking sensation.
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00:11:32,448 --> 00:11:33,896
Barbecuing with charcoal
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Has become immensely popular
Since ford's time,
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And every year, several
Million tons of wood scraps
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Are converted into high-quality
Charcoal briquettes.
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Today, briquette production
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Starts with sawdust and
Wood chips from lumber mills.
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00:11:49,413 --> 00:11:52,344
A truck unloads it all
Into a pit.
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00:11:54,896 --> 00:11:57,517
Bulldozers blend the material
Called fuel
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00:11:57,517 --> 00:12:00,206
To obtain a uniform end product.
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As the mix travels up
A conveyer,
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00:12:12,931 --> 00:12:17,517
An electromagnet removes
Any metal contaminates.
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The mix falls onto
A vibratory screener,
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Which sifts out
The larger pieces of wood.
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At this point,
The fuel is still very moist.
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To dry it,
A worm screw draws the mix
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Up into a long, rotating dryer.
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00:12:41,103 --> 00:12:47,379
The dryer heats the wood mix
To a searing 1,400 degrees.
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00:12:47,379 --> 00:12:51,103
The dryer is sealed to prevent
Oxygen from leaking in.
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00:12:51,103 --> 00:12:54,931
This allows the wood
To dry without catching fire.
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After four minutes in the dryer,
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00:13:01,310 --> 00:13:04,275
The moisture has been cooked out
Of the mix.
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00:13:05,862 --> 00:13:08,137
Workers add anthracite coal
To the hopper,
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00:13:08,137 --> 00:13:11,482
And it mixes in with the fuel.
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00:13:11,482 --> 00:13:14,448
Anthracite coal is known
For burning at high temperature.
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00:13:20,827 --> 00:13:22,931
Then they mix in lime.
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00:13:22,931 --> 00:13:26,000
Lime makes the briquettes turn
White after they're ignited --
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A visual indication
That the barbecue
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Is ready to rock 'n' roll.
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The mix, now blackened, passes
Under a second electromagnet
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00:13:35,344 --> 00:13:38,758
To remove any metal that could
Damage the equipment downstream.
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00:13:38,758 --> 00:13:42,103
Finally, workers blend in
Cornstarch,
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00:13:42,103 --> 00:13:45,103
Which binds
The ingredients together.
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00:13:50,724 --> 00:13:54,413
A worm screw supplies
The mixture to a press roll,
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00:13:54,413 --> 00:13:59,034
Where a constant spray of water
Keeps the mixture from sticking.
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00:14:09,655 --> 00:14:13,379
The press rolls compact
The mixture into briquettes.
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00:14:13,379 --> 00:14:16,551
The process takes
Just a fraction of a second.
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00:14:24,724 --> 00:14:28,413
At this point, the briquettes
Contain 35% moisture
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00:14:28,413 --> 00:14:30,344
And are very soft.
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00:14:36,000 --> 00:14:39,137
A screener shakes out fine
Material from the briquettes,
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00:14:39,137 --> 00:14:42,068
Which is recycled
Back into the process.
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00:14:46,482 --> 00:14:49,793
A sweep belt transports
And distributes the briquettes
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00:14:49,793 --> 00:14:53,310
In a 250-foot drying tunnel.
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They are heated to 280 degrees
For 2 1/2 hours.
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00:14:57,103 --> 00:15:02,103
This will reduce their moisture
Level from 35% to just 5%.
218
00:15:02,103 --> 00:15:05,482
The lower the moisture level,
The better it burns.
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00:15:07,551 --> 00:15:10,620
A conveyer transports the
Briquettes to automated scales
220
00:15:10,620 --> 00:15:13,241
That weigh them for packaging.
221
00:15:13,241 --> 00:15:18,034
Every portion is the same,
Plus or minus one briquette.
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00:15:18,034 --> 00:15:20,172
As the scales
Release the briquettes,
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00:15:20,172 --> 00:15:24,793
Robots below move bags
Into position to capture them.
224
00:15:35,724 --> 00:15:38,034
A sealing machine
Glue-seals the bags,
225
00:15:38,034 --> 00:15:41,724
Then prints a production date
And shipped code on each one.
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00:15:48,862 --> 00:15:51,482
Open the bag,
And a backyard barbecue
227
00:15:51,482 --> 00:15:54,448
Is just one match stroke away.
228
00:15:54,448 --> 00:15:59,103
And who can resist the smokey
Flavor of charcoal-grilled food?
229
00:16:08,413 --> 00:16:11,379
When we return...Turning up
A different kind of flame
230
00:16:11,379 --> 00:16:13,206
With gas-log fireplaces.
231
00:16:17,827 --> 00:16:19,448
Narrator: gas-log fireplaces
Are clean-burning,
232
00:16:19,448 --> 00:16:23,206
Fully contained units
That are growing in popularity.
233
00:16:23,206 --> 00:16:27,034
They provide instant warmth
At the flick of a switch.
234
00:16:27,034 --> 00:16:29,344
And you'll never have to head
Out on a cold winter night
235
00:16:29,344 --> 00:16:32,862
To get more logs
Or clean up the ashes.
236
00:16:43,827 --> 00:16:45,827
To make a gas-log fireplace,
237
00:16:45,827 --> 00:16:51,517
Workers first screw fittings
To a gas-control valve.
238
00:16:51,517 --> 00:16:55,724
Then they attach the valve
And gas pilot to the frame.
239
00:16:55,724 --> 00:16:58,724
The gas pilot is a small flame
That burns continuously,
240
00:16:58,724 --> 00:17:02,000
Enabling you to ignite the gas
Instantly.
241
00:17:03,724 --> 00:17:06,517
They cap the control valve
With knob extensions
242
00:17:06,517 --> 00:17:09,586
That allow the user to control
The flame's intensity
243
00:17:09,586 --> 00:17:13,103
From outside the fireplace.
244
00:17:13,103 --> 00:17:16,379
Next, they install burners
And orifices.
245
00:17:16,379 --> 00:17:20,241
The orifice controls the gas
Flow in each of the burners.
246
00:17:21,482 --> 00:17:25,172
They attach an electrical
Connection from the gas pilot
247
00:17:25,172 --> 00:17:28,689
To the control valve...
248
00:17:28,689 --> 00:17:33,758
Adjust the length of
The gas-pilot supply line...
249
00:17:33,758 --> 00:17:36,862
And screw the line
To the control valve.
250
00:17:39,241 --> 00:17:42,482
Finally, the line is attached
To the gas pilot.
251
00:17:42,482 --> 00:17:45,689
The fireplace's ignition system
Is now complete.
252
00:17:45,689 --> 00:17:49,724
Next, workers attach a safety
Device called a thermocouple
253
00:17:49,724 --> 00:17:51,206
To the control valve.
254
00:17:51,206 --> 00:17:53,034
If the flame ever goes out,
255
00:17:53,034 --> 00:17:56,172
The thermocouple
Cuts the gas supply.
256
00:17:56,172 --> 00:17:58,275
The unit now undergoes testing
257
00:17:58,275 --> 00:18:00,310
To ensure that there are
No leaks.
258
00:18:06,034 --> 00:18:08,206
What's a fireplace without logs,
259
00:18:08,206 --> 00:18:10,793
Even if they're replicas
Of the real thing?
260
00:18:10,793 --> 00:18:12,896
This factory
Makes artificial logs
261
00:18:12,896 --> 00:18:15,655
From a mixture
Of fire-resistant ceramic fibers
262
00:18:15,655 --> 00:18:18,655
And a liquid resin
That binds the fibers together.
263
00:18:27,965 --> 00:18:33,551
Workers attach a log-forming
Mold to a pumping arm...
264
00:18:33,551 --> 00:18:35,758
Then immerse the arm
In the mixture.
265
00:18:40,275 --> 00:18:42,931
The mixture
Fills the mold cavity.
266
00:18:46,655 --> 00:18:49,172
The mixture is soft
When it comes out of the mold
267
00:18:49,172 --> 00:18:50,517
And is held together
268
00:18:50,517 --> 00:18:53,551
By the dense, interwoven layers
Of fibers.
269
00:18:53,551 --> 00:18:55,758
The excess fiber is trimmed off,
270
00:18:55,758 --> 00:18:58,827
And the log is placed
On a baking rack.
271
00:19:02,275 --> 00:19:07,413
Then it's into an oven
At 450 degrees for 5 hours.
272
00:19:14,000 --> 00:19:17,206
When it comes out,
It's as hard as a log.
273
00:19:17,206 --> 00:19:21,206
Workers remove the sharp edges
With a rasp,
274
00:19:21,206 --> 00:19:25,413
Then dip the log in a mixture of
Binder and heat-resistant paint.
275
00:19:33,068 --> 00:19:35,448
Over that,
They hand-paint details
276
00:19:35,448 --> 00:19:37,965
Replicating the look
Of charred wood.
277
00:19:47,034 --> 00:19:50,551
The paint is baked on, making
This decoration permanent.
278
00:19:50,551 --> 00:19:53,137
And it'll have no problem
Taking the heat.
279
00:19:53,137 --> 00:19:55,448
The paint
Can withstand temperatures
280
00:19:55,448 --> 00:19:58,137
Up to 2,300 degrees.
281
00:20:11,137 --> 00:20:14,517
Back in the testing department,
Workers calibrate the mechanism
282
00:20:14,517 --> 00:20:16,896
That adjusts
The fireplace flame.
283
00:20:21,379 --> 00:20:25,689
They use a flowmeter to verify
The rate at which the gas flows.
284
00:20:25,689 --> 00:20:28,620
The back burner produces
A yellow flame,
285
00:20:28,620 --> 00:20:32,482
While the front burner
Gives off a reddish glow.
286
00:20:32,482 --> 00:20:36,000
Combined,
They look more realistic.
287
00:20:36,000 --> 00:20:38,482
Workers package
The individual components
288
00:20:38,482 --> 00:20:40,448
And include some lava rock
289
00:20:40,448 --> 00:20:42,896
To simulate a bed of ashes
Underneath the logs.
290
00:20:53,206 --> 00:20:57,068
It all adds up to a beautiful,
Cozy fire...
291
00:20:57,068 --> 00:20:58,827
At the flick of a switch.
292
00:21:01,551 --> 00:21:04,551
--captions by vitac--
Www.Vitac.Com
293
00:21:04,551 --> 00:21:07,551
Captions paid for by
Discovery communications, llc
294
00:21:13,517 --> 00:21:15,724
If you have any comments
About the show,
295
00:21:15,724 --> 00:21:18,448
Or if you'd like to suggest
Topics for future shows,
296
00:21:18,448 --> 00:21:20,827
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